Clutch problem. New Build

[tigerpilot]

Hi:
66CC BGF kit. New build. The clutch lever just swings back and forth. No resistance. There is a short 1" shaft but nothing pushing against the lever.
Is there a part missing or is my brain missing a part?
Thanks for your help.

[2door]

Look again. That "shaft" or pin protruding from the center of the drive sprocket is called the 'bucking bar'. There should be a ball bearing in the same hole the pin is poking out of. If that ball isn't there the clutch arm will travel loosely and not disengage the clutch.

Was it like this from the start or did you remove the clutch actuator cover and the pin. It's common for the ball to fall out without noticing while the cover was off. The ball goes in ahead of the pin. And, all of those parts need to be lubricated well with a good grade bearing grease before final assembly.

Another thought is that you're just not pushing the clutch arm far enough to feel the resistance of the clutch spring. Many first time builders under estimate the strength of that spring. You'll have trouble pushing the arm inward with your hand when it meets the spring pressure. The arm will rotate loosely outward and even toward the front but it is supposed to rotate counter-clockwise as viewed from the top looking down to disengage the clutch.
Tom

[GearNut]

The lever takes alot more pressure to disengage the clutch than you think. When you swing it inwards towards the carburetor and it stops it has just contacted the bucking bar (that 1" shaft you spoke of, there is also a single ball bearing up inside the hollow shaft behind that bucking bar).
Now push it in with all your might and you will be pushing against the strength of the clutch spring. Alot of folks find it easier to slip a piece of snug fitting pipe over the end of the release arm to afford better leverage.

In this thread, the animated pictures no longer work, but the still pictures can give you an idea of what all is inside it.
motorbicycling.com/showthread.php?t=8939


Edit:
Ha! 2door, you posted while I was trying to find the animated pictures...

[tigerpilot]

Perfect! Didn't realize there was so much travel before contacting the bearing.
I appreciate you folks very much.
Don
Naples FL